Transportation seat with release barrier fabrics

ABSTRACT

A fabric having a unique combination of stain resistance, fluid barrier properties, aesthetic characteristics and drape ability is described, and a method of making such fabrics. The fabric includes a fabric substrate that has been treated with a low surface energy stain resist compound on at least one of its surfaces, and one or more layers secured to the other of its surfaces, with the layers providing the fabric with the unique combination of characteristics. In addition, the fabric is desirably provided with flame resisting and ultraviolet resisting characteristics, to enable it to be used as a seating material for transportation vehicles. Methods for making the fabric are also described.

BACKGROUND

[0001] Traditional cars, which are typically used for family typetransportation, require an interior fabric that has pleasing aesthetics.Traditional trucks and sport utility vehicles, which are typically usedfor industrial work and weekend outdoor sports activities, require aninterior fabric that is durable to abrasion and extensive use, and thatresists soiling and water. Recent trends have been to use a hybrid oftraditional cars, trucks, and sport utility vehicles. The hybridtransportation vehicles are used not only for the family typetransportation, but also for industrial and outdoor sport activities ofthe traditional trucks and sport utility vehicles. Additionally, fabricsfor use in transportation vehicles must meet stringent requirements,such as flame resistance. Therefore, there is a need for textiles to beused in the interior of transportation vehicles, that not only have thepleasing aesthetics necessary for traditional cars but also thedurability and soil and water resistance required of the traditionalsport utility vehicle.

[0002] Heretofore, a number of approaches have been taken to makingfabrics both cleanable and liquid resistant so as to be more useful inenvironments where liquid staining is likely to occur. Vinyl coatedfabrics have been most broadly accepted for these purposes due torelatively easy cleanability and fairly low cost. These fabrics aregenerally manufactured by applying a coating of vinyl to an openscrim-type fabric, with the vinyl surface forming the outer oruser-contacting surface. However, such vinyl coated fabrics aretypically rather stiff to the touch and thereby lack the desiredappearance and feel for use in environments such as automobiles,restaurants, nursing homes, and the like where pleasing tactile andvisual perceptions by the user are considered important. Furthermore,the vinyl can tend to be uncomfortable against a user's skin, and sinceit forms a continuous, non-breathable surface, it can cause the build upof perspiration between the wearer and a seat. In addition, the vinylsurface can get extremely hot, and can be uncomfortable or even painfulto sit on in some circumstances.

[0003] Surface laminated fabrics have been utilized to enhance theaesthetic characteristics of the fabrics, but due to the generallydisjunctive adherence between the laminate film and the fabric itself,these products tend to peel, crack, and delaminate after long periods ofuse. Such laminated products also tend to lack the generally desirablefeel of standard upholstery products. Additionally, adherence of aliquid barrier film or coating to a fabric substrate is made all themore difficult when fluorochemical stain-resist treatments are applied,since such compositions by their nature tend to repel an appliedcoating.

[0004] While overcoming many of the disadvantages of the prior artmaterials described above, it has been found that the fabrics producedby the current methods may be less flexible and pliable than what wouldbe optimal for some end use applications, and in particular, thoseapplications such as intricately-shaped transportation vehicle seatingconfigurations or the like. While discussed in some respects above asrelating to automobiles and trucks, as used herein, the term“transportation vehicle seating” is intending to encompass seating orother surface areas of all types of vehicles, including but not limitedto boats, airplanes, helicopters, bicycles and motorbikes, trains,machinery such as tractors, bulldozers, and the like.

[0005] Therefore, there remains a need for fabrics that are bothcleanable and liquid resistant, have good fire resistancecharacteristics to enable them to be used in transportation vehicle typeend uses, and which have good aesthetic charactistics, including goodflexibility. There also remains a need for transportation seats having acover fabric thereon with such characteristics.

SUMMARY

[0006] In light of the foregoing, it is a general object of the presentinvention to provide a fabric which can be used for seating intransportation vehicles, which has pleasing aesthetics of the varietydesired for family type transportation vehicles in combination with thedurability and soil and water resistance generally desired for thetraditional sporty utility vehicle, and also desirably has flameresistance and UV fading resistance.

[0007] It is another object of the present invention to provide a fabricwhich possesses both stain resist and fluid barrier properties but whichalso exhibits good drape characteristics as in traditional untreatedupholstery fabrics, where a good drape is understood to mean flexibilityand/or lack of stiffness of the fabric.

[0008] It is yet another object of the invention to provide a method ofmaking a fabric having the above-stated characteristics in an economicaland efficient manner.

[0009] It is also an object of the present invention to procide atransportation seat having a fabric with the above-referencedcharacteristics.

[0010] To this end, this invention provides a fabric having, and atrasportation seat with fabric having, a unique combination of stainresistance and fluid barrier properties, while having drapecharacteristics more comparable to conventional untreated fabrics. Inthis way, the fabric is not only comfortable when used to form occupantsupport surfaces, but the fabric can also be used for applications suchas intricately configured seating configurations. In addition, thefabric also desirably has high levels of UV fading resistance and flameresistance, and forms a good bond with conventional seating foammaterials, such that the fabric is particularly useful in themanufacture of automotive seating.

[0011] Furthermore, the fabric is capable of receiving additionalmaterials such as antistats, antimicrobials, and the like to provide itwith additional performance characteristics as desired. The fabric canbe made by providing a textile fabric substrate that has been treatedwith a low surface energy stain resistance compound, and applying atleast one layer of material, and preferably two or more layers, to thefabric substrate, with the layer(s) of material cooperating with thefabric substrate to provide a fabric having a bond strength of at leastabout 0.55 lbs/in² when tested according to ASTM D751 (2001) andpreferably about 1 lbs/in² or greater, a hydrostatic pressure resistanceof at least about 50 mb and more preferably at least about 100 mb, and aoil rating of about 3 or greater when tested according to AATCC TestMethod 118-1997. Preferably, the fabric also has a burn rate of lessthan 4 inches and a ΔE of about 4.0 or less at 225 kj, as determined bySAE J1885 MAR92 (evidencing its good UV fade resistance.)

[0012] In one embodiment of the method, a low surface energy stainresistance compound is provided on at least one surface of the fabric,and stabilization material such as an acrylic material is applied to theother of its surfaces. An adhesive material is applied to thestabilization material, with the adhesive material in turn serving tobond a barrier material to the structure. In an alternative embodiment,the stabilization layer is omitted, and an FR additive can be includedin the barrier material and/or the adhesive material to enable thefabric to achieve automotive industry flame standards.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention can be better understood with reference tothe drawings, were:

[0014]FIG. 1 is a perspective partial cross-sectional view of atransportation seat incorporating the present invention.

DETAILED DESCRIPTION

[0015] In the following detailed description of the invention, specificpreferred embodiments of the invention are described to enable a fulland complete understanding of the invention. It will be recognized thatit is not intended to limit the invention to the particular preferredembodiment described, and although specific terms are employed indescribing the invention, such terms are used in a descriptive sense forthe purpose of illustration and not for the purpose of limitation.

[0016] The present invention overcomes the disadvantages of conventionalfabrics and in particular, conventional transportation vehicle fabrics,by providing a fabric that has the feel and drape (as indicated byflexibility/pliability) of a textile fabric, while having goodcleanability, fluid barrier characteristics, fire resistancecharacteristics, and durability. In addition, the invention describes amethod for making such fabrics in an efficient and economical manner.Furthermore, the fabrics of the invention can be produced to includeadditional characteristics such as UV resistance, antimicrobial agents,and the like.

[0017] The fabric of the invention desirably has a fabric substrate thathas been chemically treated with a low surface energy stain resistcompound, such as a flurorchemical, and one or more additional layersthat provide the fabric with a unique combination of cleanability, fluidbarrier characteristics, fire resistance, flexibility and durability. Inone embodiment of the invention particularly preferred for use intransportation vehicle seating end uses and the like, the fabric alsohas UV fading resistance capabilities. Preferably, the fabric has goodcleanability, as indicated by an oil rating of at least about 3 orgreater when tested according to AATCCC Test Method 118-1997, ahydrostatic pressure resistance of about 50 or greater, and preferablyabout 100 or greater, when tested according to AATCC Test Method127-1998, a burn rate of less than about 4 in/min when tested accordingto FMVSS-302 (Federal Motor Vehicle Safety Standard), and a bondstrength of about 0.55 lbs/in² or greater when tested according to ASTMD751. Particularly preferred for this application are fabrics having anoil rating of about 4 or greater, and more preferably about 5.

[0018] As noted, the fabric desirably has good fluid barriercharacteristics. To this end, the fabric desirably has a hydrostaticpressure of at least about 50 mb when tested according to AATCC TestMethod 127-1998, and more preferably about 100 mbor greater, even morepreferably about 125 mbor greater, and even more preferably about 150mbor greater. In a particularly preferred form of the invention, thefabric has a hydrostatic resistance of about 200 or greater. Inaddition, the fabric also desirably has a Spray Rating of at least about70 when tested according to AATCC Test Method 22-1996, and morepreferably at least about 75, and even more preferably at least about80. In this way, the fabric is enabled to perform well in end uses suchas the above-described automotive seating for hybrid transportationvehicles, since the fabric will withstand spills, and can be hosed offin the event it does come into contact with dirt, food, or the like.

[0019] In another aspect of the invention, the fabric desirably has goodflame resistance characteristics. Current government standards dictatethat materials to be used in automotive interior applications have aburn rate of less than 4 inches per minute. Fabrics made according tothe present invention can be produced to achieve and even exceed thislevel of fire resistance. In one embodiment of the invention, the fabrichas a burn rate of less than 4 inches per minute in each of thelengthwise and crosswise directions, and even more preferably, less thanabout 3 inches per minute in each direction, and even more preferably,less than about 2 inches per minute in each direction. Also inembodiments of the instant invention, fabrics can be produced havingfire resistance of less than about 1 inch per minute in each of thelengthwise and crosswise directions, and in some cases, may be selfextinguishing in one or both directions.

[0020] The fabric also desirably has good stability, and resistsdelamination and peeling. It is believed that this high bond strengthenables the fabric to achieve washability superior to that achieved byconventional types of barrier fabrics. By “washability”, it is meantthat the fabric is capable of withstanding laundering in conventionalwashing machines under home laundering detergent and temperatureenvironments, and more preferably under industrial conditions, which aswill be appreciated by those of ordinary skill in the art, expose thefabrics to more severe temperatures and/or detergents. Furthermore, thefabric is desirably capable of forming a strong bond with conventionalseat fabric backing materials, such as polyurethane foams. As will bereadily appreciated by those of ordinary skill in the art, such foamsare commonly provided on the back of seating type materials so provideadditional cushioning and to assist in protecting a user of the seatfrom the seat-forming parts, such as springs. The fabric desirably has abond strength of at least about 0.55 lbs/in², and more preferably atleast about 0.75 lbs/in² when secured to a polyurethane foam of thevariety commonly used as a seat material backing, when tested accordingto ASTM D751 (2001). This indicates that the fabric's structure isstrongly bonded together, and the foam is strongly bonded to the fabric.Even more preferably, the foamed fabric has a bond strength of about 1lbs/in² or greater, and even more preferably about 1.1 lbs/in² orgreater. As will be readily appreciated by those of ordinary skill inthe art, transportation vehicle manufacturers generally require overallbond strength of at least 0.55 lbs/in²; therefore, the high bondstrength achievable by the fabric of the instant invention enables it tobe used in the manufacture of transportation vehicle seating.

[0021] The fabric of the invention also desirably has good flexibilitycharacteristics, which contribute to its superior aestheticcharacteristics as opposed to prior barrier type fabrics. In particular,the fabric desirably has a bending length stiffness of about 120 mm orless according the test in ASTM D 1399 (1966), Test Method for Stiffnessof Fabrics, Option A, and even more preferably about 100 mm or less ineach of the lengthwise and crosswise directions, both when the fabric isface up and face down. Even more preferably, the fabric has a bendinglength stiffness of less than about 80 mm, and even more preferably lessthan about 60 mm, when tested in a face up orientation. As will beappreciated by those of ordinary skill in the art, the good flexibilitynot only facilitates the use of the fabric in the production ofshaped-type articles, but it enhances the comfort of items such asseating. Furthermore, the ability of the fabric to drape wellfacilitates the application of a foam backing or other additionalmaterial as desired. In addition, the fabric can have additionalproperties through the inclusion of additional compounds such asantimicrobial agents, antistats, etc. These can be applied within any ofthe other layers or as a separate operation.

[0022] As noted above, the fabric of the invention has a uniquecombination of characteristics including cleanability, fluid barriercapabilities, flame resistance and flexibility. To this end, the fabricincludes a fabric substrate having stain resistance characteristics.Preferably, the fabric substrate achieves this stain resistance by wayof a low surface energy stain resist compound, such as a fluorochemicalfinish.

[0023] The fabric substrate can be formed in any known manner, includingby weaving, knitting, braiding, nonwoven fabric manufacturing methods,thermobonding of fibers, or combinations thereof. For purposes ofexample, the fabrics discussed further herein are woven fabrics;however, it is noted that other types of fabrics can be used within thescope of the invention. Where a woven fabric is used, it is noted thatthe fabric can be plain woven, or can be woven to include a pattern,such as through a jacquard or dobby weaving method. In many forms of theinvention, it will be desirable to use a relatively “closed” fabricconstruction, meaning that the fabric does not have large open areasbetween adjacent fibers and/or yarns which make up the fabric structure.As will be readily appreciated by those of ordinary skill in the art,such constructions can be achieved through the selection of theparticular fabric construction method and set-up, and/or downstreamprocessing methods such as thermal fixation or heat-setting. The fabricsubstrate can be of any weight desired for the particular end useapplication. Where the fabric is to be used in a transportation vehicleend use application, it has been found to be desirable to incorporatefabric substrates about 5 to about 16 oz/sq yd in weight, and morepreferably about 8 oz/sq yd.

[0024] The fabric can be formed of any type of fibers and/or yarns, withthe choice utilized being selected to optimize the fabriccharacteristics for the particular fabric and anticipated end use. Forexample, it has been found that solution dyed polyester yarns performwell in the fabrics of the invention. However, it is noted that othertypes of materials including but not limited to synthetic materials suchas polyester, nylon, polypropylene, and acrylics, and natural materialssuch as cotton, wool, and the like, and blends thereof. Furthermore, thefabric substrate could comprise or consist essentially of pulp fibers,where so desired. Also, the yarn size can be selected to optimize thefabric for its particular end use. For example, large denier, finedenier, splittable fibers, microdenier fibers, spun or filament fibers,textured and flat fibers, and combinations thereof can all be usedwithin the scope of the invention. Furthermore, the fabric can be a flattype fabric (such as a plain woven fabric) or a plush or pile fabric, ora suede type fabric. In certain embodiments of the invention, it hasbeen found that fabric substrates having a hairy surface tend to haveparticularly desirable bond strength in the finished construction; suchhairy surfaces are known in the art, and are achievable through suchmeans as the inclusion of hairy yarns in the fabric structure, themechanical or chemical abrasion of the yarns forming the fabricstructure, or the like. For example, one type of yarn that has beenfound to perform well in the invention is an Albi-type textured yarn,which is a textured yarn having a hairy surface made up of a number offibrils.

[0025] The fabric substrate preferably is colored, meaning that thecolor of the fabric has an L value of about 93 or less when analyzedusing a Hunter Color Eye (such equipment being readily known by those ofordinary skill in the art.) In a preferred form of the invention, thefabric substrate will be colored due to its inclusion of solution dyedfibers and/or yarns such as solution dyed polyester, since such fibershave been found to provide desirable lightfastness and recyclability, orsolution dyed nylon, which has good resistance to discoloration fromcontact with chlorine bleach. However, other methods of achieving acolored fabric substrate are also contemplated within the scope of theinvention, including but not limited to the use of yarns dyed by othermethods such as package dyeing, yarn dyeing, or the like, or dyeing ofthe fabric substrate by any discontinuous, continuous, orsemi-continuous dye process including but not limited to piece dyeing,thermosol dyeing, jet dyeing, range dyeing, or the like. In addition,the fabric substrate could be printed or otherwise colored by any knownmethod.

[0026] As noted, the fabric substrate desirably has stain resistancecharacteristics. To this end, the fabric substrate and/or componentsmaking up the fabric substrate can be treated with a stain resistingcompound, such as a low surface energy stain resistance compound.Preferably, the stain resistance compound includes or consistsessentially of a fluorochemical (and preferably, a highly durable,highly water and oil repellant fluorochemical), and the compound isapplied to at least a first surface of the fabric substrate. Forexample, a low surface energy stain resist compound can be applied tothe fabric by a process designed to retain the compound only on thesurface to which it is applied (e.g. via certain foaming, rollapplication, spray methods, or the like), or the compound can be appliedso as to affect both surfaces of the fabric, either through applicationto the complete fabric (e.g. via a pad application method) or bysingle-side application to both fabric substrate surfaces.Alternatively, the fabric can be manufactured from components that havebeen treated with a low surface energy stain resist compound, such as byapplying the compound to the yarns prior to fabric formation. As notedabove, the application of the low surface energy stain resistingcompound will generally tend to decrease the ability of the fabricsubstrate to adhere to additional materials, and to increaseflammability. However, this compound provides the material with goodstain resisting and cleanability characteristics.

[0027] In one embodiment of the invention, the low surface energy stainresist compound-treated fabric substrate is then treated with astabilization layer which is preferably a layer of a latex orsolvent-borne polymer, plastisol, and/or or other polymer coating.Preferably the stabilization layer consists essentially of or includesan acrylic latex with a T_(g) of less than about 10° C. In aparticularly preferred form of the invention, this layer of acrylic willbe flame resistant, either inherently or through the inclusion of flameresistant compounds. Suitable flame resistant compounds include, but arenot limited to cyclic phoshonate, halogenated paraffin, brominatedcyclic, or the like, or combinations thereof. This layer has been foundto improve the dimensional stability of the fabric substrate, reducepilling, and keep the component yarns and fibers from being readilypulled out from the fabric substrate, such as by snagging. Preferably,this layer is applied at a level of about 0.25 to about 7.5 oz/sq yd,and more preferably, at a level of about 2 oz/sq yd. Where the fabricsubstrate used is only treated on a single side with the low surfaceenergy stain resist compound, the acrylic is desirably applied to theopposite surface of the fabric substrate. The acrylic can be applied inany known manner, including but not limited to coating methods, sprayapplication, extrusion methods, roller or kiss-coating applicationmethods, foaming, or the like. Preferably the stabilization layer isapplied as a continuous layer; however, it can be provided in adiscontinuous manner, such as a random or predetermined pattern, if sodesired. Knife coating is a preferred application method in that it hasbeen found to provide a good continuous coverage of the fabricsubstrate. The acrylic is desirably dried, preferably by processing itin a tenter at a temperature of about 300° to about 400° F., and morepreferably about 350° F.

[0028] In this embodiment of the invention, an adhesive material is thendesirably applied to the stabilization material-treated fabricsubstrate. The adhesive is desirably a polymeric material which includesan elastic component. Examples of adhesive materials that can be usedare metallocene polyethylene, acrylate polymers (such as methacrylatepolymers), polyurethanes, polypropylene compositions, PET polyestercompositions, polybutylene terephthalate (PBT) polyester compositions,elastomeric polyethylene, polyurethanes, elastomeric polyethylene, andcombinations or blends thereof. In a particularly preferred form of thisembodiment of the invention, the adhesive material is a metallocenepolyethylene adhesive. The thickness at which the adhesive is appliedand the application method used will be selected by the manufacturerdepending on the type of equipment he wishes to use, the type ofadhesive used, and the anticipated end use for the fabric, though it isexpected that the thickness of the adhesive will generally be about 0.1to about 5 mils, and more preferably from about 0.5 to about 3 mils. Forthis particular embodiment of the invention, it has been found thatapplication of the metallocene by way of an extrusion coating processand at a thickness of about 1-2 mils produces a good product for use intransportation vehicle seating end uses.

[0029] A barrier material is then desirably applied to the adhesivematerial layer. Examples of barrier materials that can be used include,but are not limited to urethanes, polyesters, polyolefins, olefincopolymers, rubbers (natural and synthetic), silicones, polyvinylidenechloride, polyvinylidene fluoride, polyvinyl chloride, polyvinylfluoride, plasticized versions thereof, and combinations or blendsthereof. Preferably, the barrier material has a tensile modulus of lessthan that of the fabric, and is flexible, in order to maintain bondstrength and resist delamination. In this particular embodiment of theinvention, it has been found that a 1-2 mil polyester polyurethane orpolyether polyurethane film laminated to the fabric structure by way ofthe metallocene polyethylene layer produces a desirable end product.Although lamination of a film is described in this embodiment, it isnoted that other means of providing the layer of barrier material can beprovided within the scope of the invention. For example, the barriermaterial can be applied by extrusion, coating methods, transfer methods,coating, spraying, foaming or the like. However, it has been found thatthe lamination of a polyurethane film provides a good continuous layerof the polyurethane on the fabric structure. The thickness of barriermaterial used can be selected according to the particular type ofmaterial used, the application method used, and the anticipated end useof the fabric. In this particular example of the invention, apolyurethane film having a thickness of about 0.25 to about 5 mils, andmore preferably one having a thickness of about 1 to about 3 mils, hasbeen found to perform well in the production of a fabric useful in themanufacture of transportation vehicle seating. In some embodiments ofthe invention, this barrier layer will also contain flame resistantcompounds, as will be discussed further herein.

[0030] In certain embodiments of the invention designed for particularend uses, it may be desirable to apply a foam layer to the fabric. Forexample, in some seating type applications it is desirably to provide afoam layer to provide the fabric with additional cushioning capabilitiesand to shield the fabric from such things as springs and the like whichform part of the seat support structure. In this form of the invention,it will be desirable to select an barrier material that is capable ofbonding securely to the foam material. The above-described embodiment ofthe invention having a polyurethane film barrier layer has been found tobond well with conventional urethane foams of the variety commonly usedto form automotive seating-type fabrics. The application of foam can beaccomplished by a bonding method such as adhesive bonding or the like,or can be a lamination method such as flame lamination. However, otherapplications and securement methods for the foam can also be used withinthe scope of the invention.

[0031] The fabric described in this embodiment has good drapecharacteristics (as evidenced by its high level offlexibility/pliability), good fluid barrier properties, good stainresistance, flammability resistance and bond strength. In fact, as willbe evidenced below in the Examples, the fabric made according to theinstant invention has surprisingly been found to be capable of meetingor exceeding the rigorous standards required for automotive fabrics, atsuperior cleanability and aesthetic levels than heretofore achievable.

[0032] In an alternative form of the invention, a fabric substratehaving a low surface energy stain resist treatment of the varietydescribed previously is provided. In this embodiment of the invention,the step of applying an acrylic finish is eliminated, and the adhesivelayer is applied to the fabric substrate itself. In this embodiment ofthe invention, the barrier material layer preferably includes anadditive adapted to increase its flame resistance, in order to improvethe flame resistance of the overall fabric. For example, the same baseurethane as previously described can be used, with the urethane beingmodified to incorporate an effective amount of FR additive to enable thefabric to achieve particular levels of flame resistance needed for theanticipated end use for the fabric. Suitable flame retardant agents caninclude therein cyclic phoshonate, halogenated parafin, brominatedcyclic, or the like. In a further alternative form of the invention,both the acrylic and adhesive layers are eliminated, and the elasticmaterial layer is modified to include an effective amount of FR additiveto enable it to achieve a desired level of flame resistance. However, inthis embodiment, care must be taken to ensure that the favorable levelsof flexibility and adhesion are maintained.

[0033] As noted previously, the fabric can include additionalcharacteristics such as UV fading resistance, antimicrobialcharacteristics, antistatic characteristics, etc. UV fading resistanceagents that have been found to perform well are benzotriazoles, modifiedtriazine or the like, and it has been found that these can be appliedsimultaneously with the stain resistant compounds or as a separateoperation.

[0034] Where antimicrobial features are desired, the antimicrobial agentcan be placed onto at least the first side of the fabric substrate orboth of fabric surfaces. The antimicrobial agent can be placed onto thefirst side of the fabric substrate by spraying, foam application,kiss-coat, or the like, or on both sides of the fabric substrate byimmersion coating, padding, or the like. The antimicrobial agent canalso be placed on the fabric substrate by exhausting the antimicrobialonto the fabric during the dye cycle. Additionally, the antimicrobialcan be incorporated into the fibers forming the fabric substrate. As afurther alternative, the antimicrobial materials can be provided inother of the material layers of the fabric, or as a separate independentlayer. Suitable antimicrobials include, but are not limited to, silver,silicon quat, triclosan, and organotin. The antimicrobial can be appliedat the effective minimum inhibiting concentration, such as at a level of1.00% of DM-50, an antimicrobial commercially available from ThompsonResearch of Toronto, Canada. As will be appreciated by those of ordinaryskill in the art, the inclusion of antimicrobials in the fabric mayprovide it with certain desirable characteristics such as mildewresistance, odor control, etc.

[0035] The antistatic agent can be placed onto at least the first sideof the fabric substrate. The antistatic agent can be placed onto thefirst side of the fabric substrate by spraying, foam application,kiss-coat, or the like, or on both sides of the fabric substrate byimmersion coating, padding, or the like. The antistatic agent can beplaced on the fabric substrate with the low surface energy stain resistcompound, or in a separate step with, or without, the other agentsdisposed on the fabric substrate. Suitable antistatic agents can includehighly ethoxylated esters, quartenery ammonium compounds, or the like.

[0036] While prior discussion herein of the fluid barrier properties ofthe fabric have primarily focused on the liquid barrier capabilitiesthereof, it is to be noted that the fabric can also be used as a barrierto other fluids, such as air and/or other gases. This is evidenced bythe Mullen Burst data described below, which is indicative of how wellthe fabric prevents the passage of air. While not wishing to be limitedto one theory, it is believed that in part this superior airpermeability may be attributable to the unique combination of coatingand film utilized in some of the embodiments of the invention. In otherwords, it is the inventors' belief that the provision of a coating alonemay leave poorly coated areas where a fibril or other three-dimensionalprotrusion exists on the fabric substrate. By providing a coating and afilm combination such as that described in some embodiments of theinvention, it is believed that the film serves to cover these areas ofpoor coating, thereby achieving a unique level of barrier properties.

[0037] These and other additives can be incorporated within one or moreof the other layers, or applied as a separate operation, or provided onthe original fabric substrate or as part of its original components(e.g. through the use of inherently antimicrobial or antistatic fibers.)

[0038] Although manufacture of the products has been described asencompassing the provision of several distinct layers, it is to be notedthat the method of application can be varied to optimize manufacturingefficiencies, where possible. For example, multi-component films couldbe used to provide plural layers in a single operation (e.g. such as abicomponent film having an adhesive already provided on a barrier film.)

[0039] Reflecting now to FIG. 1, there us shown a partial-cross sectionof a perspective view of a transportation seat 10 incorporating thepresent invention. The transportation seat 10, generally includes aresilient support cushion 100 with a fabric covering 200 thereon. Thefabric covering 200 can incorporate all, or some of the featuresdescribed above, and/or illustrated in the examples below.

[0040] A number of fabric samples for transportation seating wereproduced as follows: Samples were tested for a variety ofcharacteristics, including fluid barrier properties (HydrostaticPressure Test and Spray Test), stain resistance (Oil Repellancy Test),flame resistance (Burn Rate, Burn Time and Char Length Tests), bondstrength (Bond Strength Test), UV resistance (UV Test), thermal shockproperties (Thermal Shock Test), and crocking (Colorfastness to CrockingTest).

[0041] Fluid Barrier Properties: As used herein, the fluid barrierproperties are determined by the American Association of TextileChemists and Colorists (AATCC) Water Resistance: Hydrostatic PressureTest Method 127-1998, and Water Repellency: Spray Test Method 22-1996,which are hereby incorporated herein in their entirety by specificreference thereto. The release barrier fabric of the present inventionhas a hydrostatic pressure resistance of about 50 millibars or greateras determined by AATCC Water Resistance: Hydrostatic Pressure Test TM127-1998, and more preferably greater than about 100. Even morepreferably, the fabrics have a hydrostatic pressure resistance of about150 millibars or greater, and even more preferably about 200 millibarsor greater. The release barrier fabric of the present invention has awater repellency rating of about 70 (IS04) or greater, as determined bythe AATCC Water Repellency: Spray Test TM 22-1996.

[0042] Stain Resistance: As used herein, the stain resistance propertiesare determined by AATCC Oil Repellency: Hydrocarbon Resistance TestMethod 118-1997, which is hereby incorporated herein in its entirety byspecific reference thereto. The stain resistance of the release barrierfabric of the present invention is about a Grade 3 or greater, asdetermined by the AATCC Oil Repellency: Hydrocarbon Resistance Test TM118-1997, and more preferably, about a Grade 4 or greater. In certainembodiments of the invention, the oil resistance will be about 5 orgreater, on up to the maximum rating of 8.

[0043] UV Resistance: As used herein, the UV resistance properties aredetermined by SAE Recommended Practice SAE J1885 MAR92, AcceleratedExposure of Automotive Interior Trim Components Using A ControlledIrradiance Water Cooled Xenon-Arc Apparatus, which is herebyincorporated herein in its entirety by specific reference thereto. TheUV resistance of the release barrier fabric of the present inventiondemonstrates a ΔE of about 4.0 or less at 225 kj, as determined by SAEJ1885 MAR92.

[0044] Thermal Shock Properties: As used herein, the thermal shockproperties are determined by heating a fabric sample to about 100° C.,applying the sample to a simulated body of predominately water at about98° F., and measuring the temperature at the interface between thefabric sample and the simulated body after one second. The sample isapproximately a 325 square inch piece of fabric mounted to a 3 mm thickpolyurethane foam backing. The simulated body is approximately 25 poundsof water with an agar gel stabilizer, contained in a plastic bag. Thetemperature at the interface is measured by placing a thermocouple onthe surface of the plastic bag. The release barrier fabric of thepresent invention experienced temperatures of about 35° C. or less afterone second of contact with the simulated body.

[0045] Flame Resistance: As used herein, the flame resistance propertiesare determined by FMVSS-302 Test Method, which is hereby incorporatedherein in its entirety by specific reference thereto. The barrierfabrics of the invention, in some forms of the invention, desirably havea burn rate of about 4 inches or less, evidencing sufficient flameresistance to enable them to achieve current government flame resistancerequirements for automotive interior fabrics. Where “SE” appears in thetest results, it is to indicate that the fabric was self-extinguishing.

[0046] Crocking: As used herein, the crocking properties are determinedby AATCC Colorfastness to Crocking: AATCC Crockmeter Method TM 8-1996,which is hereby incorporated herein in its entirety by specificreference thereto. The crocking resistance of the release barrier fabricof the present invention is about a 3 or greater, as determined by theAATCC Colorfastness to Crocking: AATCC Crockmeter Method TM 8-1996.

[0047] Antistatic Properties: As used herein, the antistatic propertiesare determined by AATCC Electrical Resistivity of Fabrics Test Method TM76-1978, which is hereby incorporated herein in its entirety by specificreference thereto. The antistatic properties of the release barrierfabric of the present invention is about 10¹² ohms per square or less,and preferably between about 10¹⁰ and about 10¹² ohms per square, asdetermined by the AATCC Electrical Resistivity of Fabrics Test Method TM76-1978.

[0048] Bending Length Stiffness: As used herein, the bending lengthstiffness of the fabric is a measure of stiffness, where two equal andopposite forces are acting along parallel lines on either end of a stripof fabric bent into a curvature in the absence of tension, and isdetermined by ASTM D 1388 (1996), Standard Test Method for Stiffness ofFabrics, Option A.

[0049] Flexural Rigidity: As used herein, the flexural rigidity of thefabric is an interaction between the fabric weight and fabric stiffnessas shown by the way in which the fabric bends under its own weight, andis determined by ASTM D 1388 (1996), Standard Test Method for Stiffnessof Fabrics, Option B.

[0050] Circular Bend Stiffness: As used herein, the circular bendstiffness of the fabric is a measure of the resistance of the fabric tomultidirectional bending, and is determined by ASTM D 4032 (1994),Standard Test Method for Stiffness of Fabric by the Circular BendProcedure.

[0051] Bond Strength—Bond strength was tested according to ASTM D 751(2001). Generally, a 0.55 or greater bond strength is required forautomotive seating applications.

[0052] Mullen Burst—Sample F was tested according to ASTM D3786-87, withthe fabric sample being used in place of the diaphragm conventionallyused. This test method is incorporated herein by reference. The highvalues obtained indicate that the fabric will perform well as a barrierto gases such as air, and therefore will perform well in inflatable andother similar types of barrier end uses.

EXAMPLES

[0053] An approximately 8 oz/sq yd 100% polyester fabric havingapproximately 60 ends per inch and 45 picks per inch was used in each ofthe Samples A-G. The fabric was woven using 2 ply 150 filament texturedpolyester yarns in each of the warp and filling. The fabric was treatedin a variety of different ways, as described below.

[0054] Sample A—An effective amount of fluorochemical finish was paddedonto the fabric and the fabric was backcoated with a 1.5 mil coating ofEMA (ethylene methyl acrylate) by extrusion coating. The fabric wastested for adhesion and burn according to the above-described testmethods. Results of these tests are listed below in Tables A-C.

[0055] Sample B—An effective amount of a fluorochemical finish waspadded onto the fabric in the same manner as with Sample A, and thefabric was backcoated with 1.5 mil coating of apolypropylene/polybutylene blend. The fabric was tested for adhesion andburn according to the above-described test methods. Results of thesetests are listed below in Tables A-C.

[0056] Sample C—An effective amount of a fluorochemical finish waspadded onto the fabric in the same manner as with Sample A, and thefabric was backcoated with a 1.5 mil coating of an ethylene methylacrylate instead of the polypropylene/polyethylene used in Sample B. Thesample was tested for adhesion and burn according to the above-describedtest methods. Results of these tests are listed below in Tables A-C.

[0057] Sample D—An effective amount of a fluorochemical finish waspadded onto the fabric in the same manner as with Sample A, and thefabric was backcoated with an FR resistant acrylic backcoating at a rateof about 2 oz/sq yd. A 2 mil polyurethane film was laminated to theacrylic-coated surface of the fabric. The fabric was tested for bondstrength, fluid barrier properties (spray test and hydrostatic pressuretest), stain release and burn rate. The results are listed below inTables A-C.

[0058] Sample E—An effective amount of a fluorochemical finish waspadded onto the fabric in the same manner as with Sample A, and a 2 milpolyurethane film was laminated to the surface of the fabric in themanner of Sample D (though this time without the intermediate layer ofacrylic). The fabric was tested for fluid barrier properties (spray testand hydrostatic pressure test), stain release and burn rate, but thefabric rolled up and could not be tested for bond strength. The resultsare listed below in Tables A-C.

[0059] Sample F—An effective amount of a fluorochemical finish waspadded onto the fabric in the same manner as with Sample A, and anacrylic was coated onto the fabric at a level of 2 oz/sq yd. The fabricwas dried, and then a metallocene adhesive was extrusion coated at 2mils. A 2 mil film of polyether urethane (PT-5000, from DeerfieldUrethane of South Deerfield, Mass. was laminated onto the fabric by wayof the metallocene adhesive. The fabric was tested for stain resistance,fluid barrier properties, and flame resistance, and the results arelisted below in Tables A-C. The fabric was also tested for Mullen Burst,with the results being listed below in Table D. (As indicated, eightdifferent examples of two fabric samples were tested, with the resultsbeing averaged as indicated.)

[0060] Sample G—Sample G was manufactured in the same manner as SampleF, with the only difference being that a 1 mil polyester polyurethanefilm (PS-8010, also from Deerfield Urethane) was applied rather than the2 mil film of polyether urethane. The fabric was tested for the samecharacteristics as Sample F, and the results are listed below in TablesA-D. TABLE A Bond Strength Bond Strength Sample (lbs/in²⁾ Sample A 0.25Sample B 0.31 Sample C 0.28 Sample D 1.1 Sample E 0.75 Sample F 1.1Sample G 1.2

[0061] TABLE B Hydrostatic Pressure Sample Oil Rating Spray Rating (mb)Sample A 4-5 50-70  55-60 Sample B 5-6 80-100 50-55 Sample C 5-6 80-10050-55 Sample D 5 90 50 Sample E 5 100  55 Sample F 4 80 200 Sample G 580 >200

[0062] TABLE C Burn Burn Burn Burn Char Char Time Time Rate Rate LengthLength (sec) (sec) (in/min) (in/min) Sample (in) Warp (in) Filling WarpFilling Warp Filling Sample A 10 >10 96 81  6.25 >7.4 Sample B 8 >10 9890 4.9 >6.7 Sample C 8 >10 102 88 4.7 >6.8 Sample D 0 0 0 0 SE SE SampleE 0 0 0 0 SE SE Sample F 1.6 3.4 25 105 SE 1.94 Sample G 0 2.6 0 93 SE1.68

[0063] TABLE D Mullen Burst #1 #2 #3 #4 #5 #6 #7 #8 Avg. Sample F 58 4857 57 49 67 57 50 55 Sample G 50 40 40 46 48 46 36 65 46

[0064] As shown by the above examples, the fabrics made according to theinvention achieved a unique combination of bond strength of about 0.55or greater, and hydrostatic resistance of about 50 or greater (and infact, substantially higher.) In other words, the fabrics have uniquecombinations of durability and fluid barrier properties while retaininga superior level of drape than previously achievable. Furthermore, thiswas accomplished while achieving a high level of flame resistance,thereby enabling the fabrics to be used as seating fabrics intransportation vehicle end use applications.

[0065] EXAMPLE H—A 3×3 twill fabric can be formed of 3/150 polyesterwarp yarns and 3/150 fill yarns with about 35 picks per inch and about50 ends per inch. An effective amount of fluorochemical finish should bepadded onto the fabric and the fabric is backcoated with about 65 g/m²of an acrylic latex by the knife coating method. A polyetherpolyurethane film of about 20 g/m² should also be bonded to the acryliclatex coated side of the fabric with about 10 g/m² of a low melttemperature copolyester adhesive which is activated by the applicationof heated rollers applied to the outside of the film. The weight of thefinished fabric should be about 380 g/m². When the finish fabric canthen be tested for bending length stiffness, flexural rigidity, andcircular bend stiffness according to the above-described test methods,and the results should be about as listed in Tables E-G. TABLE E BendingLength Stiffness Face Up Face Down Warp Fill Warp Fill DirectionDirection Direction Direction Example (mm) (mm) (mm) (mm) Example H 12092 51 53

[0066] TABLE F Flexural Rigidity Example Warp Direction Fill DirectionExample H 2.3 Inches 2.8 Inches

[0067] TABLE G Circular Bend Stiffness Face Up Face Down Peak LoadModulus Peak Load Modulus Sample (grams force) (psi) (grams force) (psi)Example H 4897 5.5 6515 10.5

[0068] As shown by Example H, the samples of the present invention canbe formed with a bending length stiffness of about 120 mm or less, andother favorable stiffness and flexibility characteristics.

[0069] Although the fabrics of the invention have been described ashaving particular utility as transportation vehicle materials, it isnoted that the fabrics would also have utility for other end uses. Forthese alternative end uses, it may be desirable to modify such things asthe flame resistance, UV fading resistance, level of air permeability,bond strength, and the like in order to achieve a fabric particularlysuited for the anticipated end use. For example, where the fabric is tobe used as an outdoor fabric such as for outdoor furniture or awnings,it may be desirable for that fabric to have a resistance to UV fading ofabout 200 to 300 hours or greater, when tested according to AATCC TestMethod 186-2000, under fluorescent light in a spray humidityenvironment. Similarly, such things as the level of antimicrobialresistance and flexibility may also be engineered to achieve an optimalend product for a particular end use.

[0070] In the specification there has been set forth a preferredembodiment of the invention, and although specific terms are employed,they are used in a generic and descriptive sense only and not forpurpose of limitation, the scope of the invention being defined in theclaims.

What is claimed is:
 1. A transportation seat comprising: a resilientsupport cushion; a fabric covering disposed on the resilient supportingcushion, the fabric covering including: a fabric substrate including alow surface energy stain resisting compound; an adhesive layer securedto one surface of the fabric substrate; and a barrier layer secured tosaid adhesive layer; and, said fabric covering having a bending lengthstiffness of about 120 mm or less in each of a lengthwise and crosswisedirection in each of face up and face down orientations when testedaccording to ASTM D 1399 (1966), Test Method for Stiffness of Fabrics,Option A, and a hydrostatic pressure resistance of about 50 mb orgreater when tested according to AATCC test Method 127-1998.
 2. Thetransportation seat according to claim 1, further comprising astabilization layer between said fabric substrate and said adhesivelayer.
 3. The transportation seat according to claim 2, wherein saidstabilization layer is a substantially continuous layer.
 4. Thetransportation seat according to claim 2, wherein said stabilizationlayer comprises an acrylic material.
 5. The transportation seataccording to claim 1, wherein said fabric covering has a Mullen Burststrength of about 40 psi or greater.
 6. The transportation seataccording to claim 1, wherein said fabric covering has a Mullen Burststrength of about 50 psi or greater.
 7. The transportation seataccording to claim 1 wherein said fabric covering is bonded to a foamlayer at a bond strength of about 0.55 lb/in² or greater when testedaccording to ASTM D751 (2001).
 8. The transportation seat according toclaim 1, wherein said fabric covering has a bending length stiffness ofabout 100 mm or less.
 9. The transportation seat according to claim 1,wherein said fabric covering has a bending length stiffness of about 90mm or less.
 10. The transportation seat according to claim 1, whereinsaid fabric covering has a hydrostatic pressure resistance of about 100mb or greater when tested according to AATCC Test Method 127-1998. 11.The transportation seat according to claim 1, wherein said fabriccovering has a hydrostatic pressure resistance of about 150 mb orgreater when tested according to AATCC Test Method 127-1998.
 12. Thetransportation seat according to claim 1, wherein said fabric coveringhas a hydrostatic pressure resistance of about 200 mb or greater whentested according to AATCC Test Method 127-1998.
 13. A transportationseat comprising: a resilient support cushion; a fabric covering disposedon the resilient cushion, the fabric covering including a textilesubstrate and one or more additional layers secured to one surface ofsaid textile substrate, said fabric covering having a bending lengthstiffness of about 120 mm or less in each of a lengthwise and crosswisedirection in each of face up and face down orientations according toASTM D 1399 (1966), Test Method for Stiffness of Fabrics, Option A, anda hydrostatic pressure resistance of about 50 mb or greater when testedaccording to AATCC Test Method 127-1998.
 14. The transportation seataccording to claim 13, wherein said fabric covering has a bending lengthstiffness of about 100 mm or less in each of the lengthwise andcrosswise directions in each of a face up and face down orientations.15. The transportation seat according to claim 13, wherein said fabriccovering has a hydrostatic pressure resistance of about 100 mb orgreater.
 16. The transportation seat according to claim 13, wherein saidfabric covering has a hydrostatic pressure resistance of about 150 mb orgreater.
 17. The transportation seat according to claim 13, wherein saidfabric covering has a hydrostatic pressure resistance of about 200 mb orgreater.
 18. The transportation seat according to claim 13, wherein saidfabric covering has a burn rate of about 4 inches or less when testedaccording to FMVSS-302 Test Method.
 19. The transportation seataccording to claim 13, wherein said fabric covering has a burn rate ofabout 3 inches or less when tested according to FMVSS-302 Test Method.20. The transportation seat according to claim 13, wherein said fabriccovering has a burn rate of about 2 inches or less when tested accordingto FMVSS-302 Test Method.
 21. The transportation seat according to claim13, wherein said fabric covering has a spray rating of about 70 orgreater when tested according to AATCC Test Method 22-1996.
 22. Thetransportation seat according to claim 13, wherein said fabric coveringhas a spray rating of about 80 or greater when tested according to AATCCTest Method 22-1996.
 23. The transportation seat according to claim 13,wherein said fabric covering has an oil rating of about 3 or greaterwhen tested according to AATCC Test Method 118-1997.
 24. Thetransportation seat according to claim 13, wherein said fabric coveringhas an oil rating of about 4 or greater when tested according to AATCCTest Method 118-1997.
 25. The transportation seat according to claim 13,wherein said fabric covering has an oil rating of about 5 or greaterwhen tested according to AATCC Test Method 118-1997.
 26. Thetransportation seat according to claim 13, wherein said fabric coveringhas a Mullen Burst strength of about 50 psi when tested according toASTM D751 (2001).
 27. The transportation seat according to claim 13,wherein said fabric covering has a burn rate of about 4 inches or lesswhen tested according to FMVSS-302 Test Method, and said fabricsubstrate includes a low surface energy stain resisting compound. 28.The transportation seat according to claim 27, wherein said fabriccovering forms a part of a transportation vehicle.
 29. Thetransportation seat comprising: a resilient support cushion; a fabriccovering disposed on the resilient supporting cushion, the fabriccovering including a fabric substrate including a low surface energystain resisting compound and at least one layer secured to one surfaceof said fabric, said fabric covering having a hydrostatic pressureresistance of at least about 125 mb when tested according to AATCC TestMethod 127-1998 and a bending length stiffness of about 120 mm or lessin each of a lengthwise and crosswise direction in each of face up andface down orientations according to ASTM D 1399 (1966), Test Method forStiffness of Fabrics, Option A.
 30. The transportation seat according toclaim 29, wherein said fabric covering has a burn rate of about 4 inchesor less when tested according to FMVSS-302 Test Method.